Junction connector for wire harnesses

Abstract

A junction connector is provided that can be connected with wire harnesses from different directions. The junction connector includes a shell containing junction circuits including at least two connector-fitting portions oriented in different directions. The junction circuits include a plurality of bus bar layers, each of the bus bar layers including a bus bar group. Each of the bus bars is formed into the shape of a strip having two end tabs and are aligned at a given interval from each other along the same direction. The bus bar layers are superposed so that the bus bars groups are arranged in a skewed direction relative to each other, thereby forming cross points between the bus bar groups, and the bus bars are joined at the cross points, for example by bonding, thereby forming junction circuits. Connectors bound to wire harnesses are then fitted into the connector-fitting portions, so that the electrical cables in the wire harnesses are splice-connected through the bus bars.

What is claimed:  
     
       1. A junction connector comprising a shell which contains junction circuits and at least two connector-fitting portions oriented along different directions, said junction circuits comprising at least a first bus bar layer and a second bus bar layer, said first and second bus bar layers including first and second sets of bus bars, respectively, said first and second sets of bus bars having two respective end tabs and being aligned at a given interval from each other in the same direction, respectively, each of said connector-fitting portions projecting from said shell and being configured to receive said respective end tabs protruding therein and to electrically connect said respective end tabs and a connector fitted on said connector-fitting portion, said second bus bar layer being superposed on said first bus bar layer such that the direction of said second set of bus bars is skewed relative to that of said first set of bus bars, thereby forming cross points between said first set of bus bars and said second set of bus bars, said first and second sets of bus bars being joined at said cross points, thereby forming junction circuits. 
     
     
       2. The junction connector according to  claim 1 , further comprising, in addition to said first and second bus bar layers, a third bus bar layer with a corresponding third set of bus bars and end tabs likewise arranged, wherein said third bus bar layer is superposed on said second bus bar layer such that the direction of said third set of bus bars is skewed relative to that of said second set of bus bars, thereby forming cross points between said second set of bus bars and said third set of bus bars, said second and third sets of bus bars being bonded through said cross points, thereby forming junction circuits. 
     
     
       3. The junction connector according to  claim 2 , wherein a second insulating sheet is interposed between said second bus bar layer and said third bus bar layer, said second insulating sheet being provided with openings at positions corresponding to said cross points, and said second set of bus bars and said set of third bus bars are bent into said openings, so that said second set of bus bars is brought into contact with said third set of bus bars through said openings, and said second set of bus bars is joined to said third set of bus bars. 
     
     
       4. The junction connector according to  claim 1 , wherein an insulating sheet is interposed between said first bus bar layer and second bus bar layer, said insulating sheet being provided with openings at positions corresponding to said cross points, said first set of bus bars included in said first bus bar layer is bent into said openings and is bent into contact with said second set of bus bars included in said second bus bar layer, and said first set of bus bars is joined to said second set of bus bars. 
     
     
       5. The junction connector according to  claim 4 , further comprising, in addition to said first and second bus bar layers, a third bus bar layer with a corresponding third set of bus bars and end tabs likewise arranged, wherein said third bus bar layer is superposed on said second bus bar layer such that the direction of said third set of bus bars is skewed relative to that of said second set of bus bars, thereby forming cross points between said second set of bus bars and said third set of bus bars, said second and third sets of bus bars being joined at said cross points, thereby forming junction circuits. 
     
     
       6. The junction connector according to  claim 5 , wherein a second insulating sheet is interposed between said second bus bar layer and said third bus bar layer, said second insulating sheet being provided with openings at positions corresponding to said cross points, and said second set of bus bars and said third set of bus bars are bent into said openings, so that said second set of bus bars is brought into contact with said third set of bus bars through said openings, and said second set of bus bars is joined to said third set of bus bars. 
     
     
       7. The junction connector according to  claim 1 , wherein at least one of said first and second bus bar layers includes at least one bus bar comprising at least one of upwardly and downwardly bent end tabs, and said shell comprises corresponding upwardly and downwardly connector-fitting portions. 
     
     
       8. The junction connector according to  claim 7 , wherein an insulating sheet is interposed between said first bus bar layer and second bus bar layer, said insulating sheet being provided with openings at the positions corresponding to said cross points, said first set of bus bars included in said first bus bar layer is bent into said openings and is bent into contact with said second set of bus bars included in said second bus bar layer, and said first set of bus bars is joined to said second set of bus bars. 
     
     
       9. The junction connector according to  claim 8 , further comprising, in addition to said first and second bus bar layers, a third bus bar layer with a corresponding third set of bus bars and end tabs likewise arranged, wherein said third bus bar layer is superposed on said second bus bar layer such that the direction of said third set of bus bars is skewed relative to that of said second set of bus bars, thereby forming cross points between said second set of bus bars and said third set of bus bars, said second and third sets of bus bars being joined at said cross points, thereby forming junction circuits. 
     
     
       10. The junction connector according to  claim 7 , further comprising, in addition to said first and second bus bar layers, a third bus bar layer with a corresponding third set of bus bars and end tabs likewise arranged, wherein said third bus bar layer is superposed on said second bus bar layer such that the direction of said third set of bus bars is skewed relative to that of said second set of bus bars, thereby forming cross points between said second set of bus bars and said third set of bus bars, said second and third sets of bus bars being joined at said cross points, thereby forming junction circuits. 
     
     
       11. The junction connector according to  claim 10 , wherein a second insulating sheet is interposed between said second bus bar layer and said third bus bar layer, said second insulating sheet being provided with openings at positions corresponding to said cross points, and said second set of bus bars and said third set of bus bars are bent into said openings, so that said second set of bus bars is brought into contact with said third set of bus bars through said openings, and said second set of bus bars is joined to said third set of bus bars. 
     
     
       12. The junction connector according to  claim 1 , wherein said shell defines peripheral rims, said second bus bar layer is superposed on said first bus bar layer such that said second set of bus bars is arranged perpendicular to said first set of bus bars, said shell includes at least three connector-fitting portions which are provided on said peripheral rims and separated at an angle of 90 degrees from each other around the central axis of said shell, and said connector-fitting portions contain said end tabs of said first and second sets of bus bars. 
     
     
       13. The junction connector according to  claim 12 , wherein an insulating sheet is interposed between said first bus bar layer and second bus bar layer, said insulating sheet being provided with openings at the positions corresponding to said cross points, said first set of bus bars included in said first bus bar layer is bent into said openings and is bent into contact with said second set of bus bars included in said second bus bar layer, and said first set of bus bars are joined to said second set of bus bars. 
     
     
       14. The junction connector according to  claim 13 , further comprising, in addition to said first and second bus bar layers, a third bus bar layer with a corresponding third set of bus bars and end tabs likewise arranged, wherein said third bus bar layer is superposed on said second bus bar layer such that the direction of said third set of bus bars is skewed relative to that of said second set of bus bars, thereby forming cross points between said second set of bus bars and said third set of bus bars, said second and third sets of bus bars being joined at said cross points, thereby forming junction circuits. 
     
     
       15. The junction connector according to  claim 12 , further comprising, in addition to said first and second bus bar layers, a third bus bar layer with a corresponding third set of bus bars and end tabs likewise arranged, wherein said third bus bar layer is superposed on said second bus bar layer such that the direction of said third set of bus bars is skewed relative to that of said second set of bus bars, thereby forming cross points between said second set of bus bars and said third set of bus bars, said second and third sets of bus bars being joined at said cross points, thereby forming junction circuits. 
     
     
       16. The junction connector according to  claim 15 , wherein a second insulating sheet is interposed between said second bus bar layer and said third bus bar layer, said second insulating sheet being provided with openings at positions corresponding to said cross points, and said second set of bus bars and said third set of bus bars are bent into said openings, so that said second set of bus bars is brought into contact with said third set of bus bars through said openings, and said second set of bus bars is joined to said third set of bus bars. 
     
     
       17. The junction connector according to  claim 12 , wherein at least one of said first and second bus bar layers includes at least one bus bar comprising at least one of upwardly and downwardly bent end tabs, and said shell comprises corresponding upwardly and downwardly connector-fitting portions. 
     
     
       18. The junction connector according to  claim 17 , further comprising, in addition to said first and second bus bar layers, a third bus bar layer with a corresponding third set of bus bars and end tabs likewise arranged, wherein said third bus bar layer is superposed on said second bus bar layer such that the direction of said third set of bus bars is skewed relative to that of said second set of bus bars, thereby forming cross points between said second set of bus bars and said third set of bus bars, said second and third sets of bus bars being joined at said cross points, thereby forming junction circuits. 
     
     
       19. The junction connector according to  claim 17 , wherein an insulating sheet is interposed between said first bus bar layer and second bus bar layer, said insulating sheet being provided with openings at the positions corresponding to said cross points, said first set of bus bars included in said first bus bar layer is bent into said openings and is bent into contact with said second set of bus bars included in said second bus bar layer, and said first set of bus bars is joined to said second set of bus bars. 
     
     
       20. The junction connector according to  claim 19 , further comprising, in addition to said first and second bus bar layers, a third bus bar layer with a corresponding third set of bus bars and end tabs likewise arranged, wherein said third bus bar layer is superposed on said second bus bar layer such that the direction of said third set of bus bars is skewed relative to that of said second set of bus bars, thereby forming cross points between said second set of bus bars and said third set of bus bars, said second and third sets of bus bars being joined at said cross points, thereby forming junction circuits.